ClimateMaster CS Series Manual de usuario

CS/CL Series

Console Air Conditioners

Water Source Heat Pumps

Installation, Operation, &

Maintenance Instructions

Page 2

TABLE OF CONTENTS Page

General Information 3

Inspection 3

Introduction 3

Storage 3

Unit Protection 3

Pre-Installation 4

Installation 4

Supply and Return Hoses 4

Installation of Supply and Return Piping 5

Condensate Piping 5

Electrical Wiring 5

Optional Night Setback Control 5

Optional CMC-2000 Controller 6

Optional Wall Mounted Thermostat 6

Start-Up Preperation 7

System Checkout 8

Unit Start-Up 9

Maintenance 11

Warranty 13

Page 3

To avoid equipment damage, do not use these units as

a source of heating or cooling during the construction

process. The mechanical components and filters used

in these units quickly becomes clogged with

construction dirt and debris which may cause system

damage.

To avoid the release of refrigerant into the

atmosphere, the refrigerant circuit of this unit must

only be serviced by technicians which meet local, state

and federal proficiency requirements.

All refrigerant discharged from this unit must be

recovered without exception. Technicians must follow

industry accepted guidelines and all local, state and

federal statutes for the recovery and disposal of

refrigerants.

When a compressor is removed from this unit, system

refrigerant circuit oil will remain in the compressor.

To avoid leakage of compressor oil, the refrigerant

lines of the compressor must be sealed after it is

removed.

Storage

CAUTION: DO NOT store or install CS/CL units in

corrosive environments or in locations subject to

temperature or humidity extremes (e.g., attics,

garages, rooftops, etc.). Corrosive conditions and high

temperature or humidity can significantly reduce

performance, reliability, and service life. Always

move units in an upright position. Tilting units on

their sides may cause equipment damage.

Upon the arrival of the equipment at the job site, immedi-

ately store units in their shipping cartons in a clean, dry

area. Store units in an upright position at all times.

Stack units a maximum of 3 units high. Use pallets to

separate each layer of units. Do not remove equipment

from shipping cartons until equipment is required for

installation.

Unit Protection

Cover CS/CL units on the job site with either shipping

cartons, vinyl film, or an equivalent protective covering.

Cap the open ends of pipes stored on the job site. In areas

where painting, plastering, or the spraying of fireproof

material has not been completed, all due precautions

must be taken to avoid physical damage to the units and

GENERAL INFORMATION

Inspection

Upon receipt of shipment, carefully check the shipment

against the bill of lading. Verify all CS/CL units have

been received. Inspect each unit for damage. Be certain

the carrier makes proper notation on the delivery receipt

of all shortages and noticeable damage and he completes

a Carrier Inspection Report. Concealed damage not

discovered during unloading must be reported to the

carrier within fifteen (15) days of receipt of shipment.

NOTE: It is the responsibility of the purchaser to file

all necessary claims with the carrier. Notify the

ClimateMaster Traffic Department within fifteen (15)

days of receipt of all damaged shipments.

Introduction

ClimateMaster Console Air Conditioner Water Source

Heat Pump units are decentralized room terminals

designed for field connection to a closed-circuit piping

loop. They are offered in capacities ranging from 6,800

to 17,600 BTUH cooling and 8,500 to 21,000 BTUH

heating.

Units are typically installed in perimeter zones, usually

under windows. Supply air is discharged directly into the

conditioned space through discharge grills located in the

top of the unit.

contamination by foreign material. Physical damage and

contamination may prevent proper start-up and may

result in costly equipment clean-up.

Examine all pipes, fittings, and valves before installing

the system components. Remove any dirt found on these

components.

Pre-Installation

Installation, operation and maintenance instructions are

provided with each unit. Before unit start-up, read all

manuals and become familiar with the unit and its

operation. Thoroughly check out the system before

operation. Complete the inspections and instructions

listed below to prepare a CS/CL unit for installation.

1. Compare the electrical data on the unit nameplate

with ordering and shipping information to verify that

the correct unit has been shipped.

2. Keep both the chassis and cabinet covered with the

shipping carton until all plastering, painting, and

finish work is complete and it is time to install the

chassis and cabinet.

3. Verify that the refrigerant tubing is free of kinks or

dents, and that it does not touch other unit compo-

nents.

4. Inspect all electrical connections. Connections must

be clean and tight at the terminals.

Page 4

The installation of ConsoleWater Source Heat Pumps and

all associated components, parts and accessories that

make up the installation shall be in accordance with the

regulations of ALL Authorities having jurisdiction and

MUST conform to all applicable Codes. It is the

responsibility of the Installing Contractor to determine

and comply with ALL applicable Codes and Regulations.

NOTE: An Installation Checklist is provided at the

end of this manual. Complete this checklist after all

installation procedures are completed. A periodic

maintenance checklist provided in the Maintenance

section outlines recommended maintenance schedules.

A Start-Up Inspection Log is also included at the end

of this manual to encourage thorough unit checkout

at initial start-up. These checklists are not a substitute

for the detailed information found in the Installation

section of this manual.

INSTALLATION

1. CS/CL units are typically installed along an outside

wall of the room. Provide adequate space in front of

the unit for service and maintenance. Locate the

Console Air Conditioner so that it provides adequate

air circulation throughout the room.

2. Unpack the CS/CL Unit from the shipping carton.

Remove the front cabinet by lifting up and away

from the backplate. Protect the cabinet from damage

during installation by returning it to its original vinyl

pack until required.

3. Using a carpenter's square and a level, ensure the

unit is level. Shim the unit if necessary to assure

proper installation.

CAUTION: Poor or inadequate installation may

result in noisy unit operation or unattractive

installation.

4. Select the proper fasteners to connect the backplate

securely to the wall.

5. Fasten the backplate onto the wall through the screw

holes located in the back flange. Secure the subbase

in place.

6. Make all necessary electrical connections as de-

scribed in the Electrical Wiring section of this

manual. Consult the wiring diagram to ensure proper

hook-up.

CAUTION: RH Units - Entering Water is upper pipe.

LH Units - Entering Water is lower pipe.

7. Connect the final piping as described in the Supply and

Return Piping and Condensate Piping section of the

manual. Install shut-off valves, piping and/or hoses

and other accessories as specified.

8. Before making the final water connections, flush the

system as described in the Start Up section of this

manual. After flushing the system, connect piping

and hoses to the proper supply, return and conden-

sate connections of the unit.

NOTE: When necessary, use adapters to connect

hoses.

9. Reinstall the front cabinet by carefully lowering the

front cabinet over the chassis onto the backplate.

10. Install any other system components as required

following manufacturer's instructions.

Supply and Return Hoses

Optional pressure-rated hose assemblies are available for

use with ClimateMaster CS/CL Units. Use the following

guidelines when installing supply and return hose

assemblies.

1. Install supply and return hoses fitted with swivel-

joint fittings at one end to prevent the hose from

twisting.

2. Use male adapters to secure the hose assembly to the

unit and the riser.

3. Do not allow the hose to twist during installation.

Twisting may damage the hose wall or the rubber

compound.

4. Use pipe joint compound sparingly on the male pipe

threads of the fitting adapters.

5. Prevent sealant from reaching the flared surfaces of

the joint.

6. Do not use pipe joint compound when teflon thread

tape is pre-applied to hose assemblies or when

flared-end connections are used.

7. Maximum torque which may be applied to brass

fittings is 30 foot pounds. When a torque wrench is

not used, tighten brass fittings finger-tight plus one

quarter turn.

8. Tighten steel fittings as necessary.

9. Shut-off/balancing valves, flow indicators, and drain

tees in the supply runout and return at each floor aid

in loop balancing and servicing.

Page 5

Supply and Return Piping

System piping MUST comply with all applicable codes.

1. Install a drain valve at the base of each supply and

return riser to enable system flushing at start-up and

during routine servicing.

2. Install shut-off/balancing valves and unions at each

unit to allow unit removal for servicing.

NOTE: If flex hoses are used, unions are not

necessary.

3. Install strainers at the inlet of each system circulating

pump.

NOTE: Since loop temperature is normally between

60°and 90°F, pipe sweating and heat loss does not

occur at normal ambient conditions. Insulation must

be installed on loop water piping on those sections

which run through unheated areas or are located

outside the building.

Condensate Piping

Connect the unit condensate drain to the building

condensate drain with a flexible, nonpressure-rated 5/8

inch I.D. plastic hose. Avoid kinks in this hose to ensure

an unobstructed flow of condensate from the unit to the

drain.

The horizontal run of the condensate hose is usually too

short to pose any drainage problems however, the

horizontal run of condensate line ought to be pitched at

least one inch for every 10 feet of run in the direction of

flow. Avoid low points and unpitched piping since dirt

collects in these areas and may cause stoppage and

overflow.

Field installation of a trap or vent is not required unless

specified by local codes. CS/CL units are designed in a

blow-through configuration. The condensate drain pan is

located on the outlet side of the blower so that the

pressure in the drain pan is higher than the atmosphere.

Electrical Wiring

To avoid possible injury or death due to electrical

shock, open the power supply disconnect switch and

secure it in an open position during installation.

CAUTION: Use only copper conductors for field

installed electrical wiring. Unit terminals are not

designed to accept other types of conductors.

All field installed wiring, including the electrical ground,

MUST comply with the National Electrical Code as well

as applicable local codes. In addition, all field wiring

must conform to the Class II temperature limitations

described in the NEC.

Consult the unit wiring diagram located on the inside of

the compressor access panel to ensure proper electrical

hookup. The installing (or electrical) contractor must

make the field connections shown in Figure 1 when using

field supplied disconnect.

Modify the transformer connection for units rated

208-230 volts with a 24-volt transformer when the actual

power supply is 230 volts. Refer to the unit wiring

diagram for details of this procedure.

Make all final electrical connections with a length of

flexible conduit to minimize vibration and sound

transmission to the building.

104 Volts min - 127 Volts max

197 Volts min - 250 Volts max

238 Volts min - 292 Volts max

115/60/1

208/230/60/1

265/60/1

Table 1 Operating Voltages

Volts/Hz/Phase Operating Range

Optional Night Setback Control

An optional hard-wired night setback system (NSB) is

available. This system consists of a central (or zone)

night setback control panel and an individual NSB relay

at each heat pump.

Refer to unit wiring diagrams for specific night setback

options and correct method of wiring.

Page 6

Optional CMC-2000 Series Electronic

Controller

A solid state CMC-2000 Series controller is available as

an option to the standard electro-mechanical line voltage

thermostat control.

The CMC-2001 Controller is standard when a 24V

remote thermostat is used.

Refer to the CMC-2000 Series Electronic Controller

Installation and Operating Manual (p/n 69626515)

shipped with the controller for installation and operating

instructions.

Optional Wall-Mounted Thermostat

CS/CL WSHP units are built with standard internal

thermostats in either manual changeover (MCO) or

automatic changeover (ACO) configuration. No external,

field-installed low-voltage wiring is required.

When desired, the unit can be furnished with a 24-volt

control circuit which is field-wired to a ClimateMaster-

supplied accessory remote thermostat.

Zone integrity must be maintained to efficiently control

units or groups of units. Unless zones of control are

considered and accounted for, adjacent units may operate

in heating and cooling modes simultaneously.

Low-voltage wiring between the unit and the wall

thermostat must comply with all applicable electrical

codes (i.e., NEC and local codes), and be completed

before the unit is installed.

Table 2 lists recommended wire sizes and lengths to

install the thermostat. The total resistance of low-voltage

wiring must not exceed 1 ohm. Any resistance in excess

of 1 ohm may cause the control to malfunction because

of high voltage drop.

WIRE SIZE MAX. WIRE LENGTH*

18-Gauge 75 Feet

16-Gauge 125 Feet

14-Gauge 200 Feet

*Length = Physical distance from thermostat to unit.

Table 2 - Recommended Thermostat Wire Sizes

Field Supplied

Disconnect Switch

Heat Pump

Room Thermostat

A= Two power wires on single-phase units: three power wires on three-phase units. B= 1 heat /1 cool /manual or Auto

Change-over remote 24V thermostat. Note: All customer-supplied wiring to be copper only and must conform to NEC

and local electrical codes. Wiring shown with dashed lines must be field-supplied and field-installed.

DISCONNECT ELECTRICAL POWER

SOURCE TO PREVENT INJURY OR

DEATH FROM ELECTRICAL SHOCK.

CAUTION: USE COPPER

CONDUCTORS ONLY TO PREVENT

EQUIPMENT DAMAGE.

Figure 1 Typical Field Installed Wiring

Note: If a ClimateMaster ET Series Electronic

Thermostat is used then the wiring between the

thermostat and the unit must be a 4 shielded

conductor. See ET Thermostat IOM (p/n 69197318).

Page 7

System Cleaning and Flushing

Cleaning and flushing the unit is the single most impor-

tant step to ensure proper start-up and continued efficient

operation of the system. Follow the instructions below to

properly clean and flush the system:

To prevent injury or death due to electrical shock or

contact with moving parts, open unit disconnect

before servicing unit.

1. Verify that electrical power to the unit is discon-

nected and that the heat rejector is de-energized

2. Install the system with the supply hose connected

directly to the return riser valve. Use a single length

of flexible hose as illustrated in Figure 2 below.

NOTE: When one hose is too short to make the

connection without exceeding the minimum bend

radius of the hose, substitute two length of flexible

hose joined together with a field-supplied, standard

MPT coupling. Use the adapter provided with the

hose kit as shown in Figure 3.

3. Fill the system with water, leaving the air vents

open. Bleed all air from the system but do not allow

the system to over flow. Check the system for leaks

and make any required repairs. Adjust the water and

air level in the expansion tank.

4. With strainers in place, start the pumps. Systemati-

cally check each vent to ensure that all of the air is

bled from the system.

5. Verify that make-up water is available and adjusted

to properly replace any space remaining when all

air is evacuated. Check the system for leaks and

make any additional repairs required.

START-UP PREPARATION

6. Set the boiler to raise the loop temperature to

approximately 85°F. Open the drain at the lowest

point in the system. Verify that make-up water

replacement rate equals rate of bleed. Continue to

bleed the system until the water appears clean or for

at least three hours whichever is longer.

7. Completely drain the system.

8. Refill the system with clean, chemically treated

water. Since water varies for each locality, contact a

local water treatment company for the correct

cleaning chemicals to use in your area.

CAUTION: To avoid possible damage to piping

systems constructed of plastic piping, DO NOT allow

loop temperature to exceed 110°F.

9. Circulate the solution for a minimum of eight to 24

hours. At the end of this period, shut off the circulat-

ing pump and drain the solution. Repeat system

cleaning if necessary.

10. When the cleaning process is complete, remove the

short-circuit hoses. Re-connect the hoses to the

proper supply and return the connections to the unit.

Refill the system and bleed off all air.

11. Test the system pH with litmus paper. The system

water should be slight alkaline (pH 7.5 to 8.5). Add

chemicals as appropriate to maintain acidity levels.

CAUTION: DO NOT use "Stop-Leak" or any similar

chemical agent in this system. Addition of these

chemicals to the loop water will foul the system and

will inhibit unit operation.

12. When the system is successfully cleaned, flushed,

refilled and bled, check the main system panels,

safety cutouts and alarms. Set controls to properly

maintain loop temperature.

NOTE: Use standard coupling (field-supplied) and

hose adapters to join 2 hoses

Figure 3

.5" Flexible Hose

Brass Adapter

(.5" MPT x .5"

Male Flare)

Return Valve

Supply Valve

Floor Line

Figure 2

Page 8

9. Freeze Protection for Water System: Verify

freeze protection is provided for the outdoor portion

of the loop water system. Inadequate freeze protec-

tion can lead to expensive tower and system piping

repairs.

CAUTION: To avoid equipment damage, DO NOT

leave system filled in a building without heat during

the winter unless anti-freeze is added to system water.

Condenser coils never fully drain by themselves and

will freeze unless winterized with anti-freeze.

10. System Water Loop: Verify all air is bled from

the system. Air in the system impedes unit operation

and causes corrosion in the system piping.

11. Unit Filters: To avoid system damage, ensure

the unit filter is clean.

12 Unit Fans: Manually rotate fans to assure free

rotation. Ensure fans are properly secured to the fan

shaft. Do not oil fan motors on start-up since they

are lubricated at the factory.

13. System Control Center: To ensure control of the

temperature set-points for operation of the system’s

heat rejector and boiler, examine the system control

and alarm panel for proper installation and opera-

tion.

14. Miscellaneous: Note any questionable aspects of

the installation.

1. Voltage: Ensure voltage is within the utilization

range specifications of the unit compressor and fan

motor.

2. System Water Temperature: Ensure it is within

an acceptable range to facilitate start-up. (When

conducting this check, also verify proper heating and

cooling set points.)

3. System Water pH: Verify system water acidity.

(pH = 7.5 or 8.5) Proper pH promotes the longevity

of hoses and heat exchangers.

4. System Flushing: Properly clean and flush

system periodically. Ensure all supply and return

hoses are connected end-to-end to facilitate system

flushing and prevent fouling of the heat exchanger

by system water. Water used in the system must be of

potable quality and clean of dirt, piping slag, and

chemical cleaning agents.

5. Closed-Type Cooling Tower or Open Tower

with Heat Exchanger: Check equipment for proper

temperature set points and operation.

6. Balanced Water Flow Rate to Heat Pump::

Verify the inlet and outlet water temperatures are

recorded as each heat pump unit is started. This

check will eliminate nuisance unit trip-outs resulting

from water velocities which are either too low or too

high; it can also prevent the occurrence of erosive

water flow rates.

7. Standby Pump: Verify the standby pump is

properly installed and in operating condition.

8. System Controls: To ensure no catastrophic

system failures occur, verify system controls are

functioning and the sequencing is correct.

When the installation is complete and the system is cleaned and flushed, follow the System Checkout procedure outline below.

SYSTEM CHECKOUT

❏

Page 9

UNIT START-UP

Air Limits Cooling Heating Cooling Heating

Min. Ambient Air 50°F50°F40°F40°F

Rated Ambient Air 80°F70°F80°F70°F

Max. Ambient Air 100°F85°F 100°F85°F

Min. Entering Air 50°F50°F50°F40°F

Rated Entering Air db/wb 80/67°F70°F 80/67°F70°F

Max. Entering Air db/wb 100/83°F80°F 100/83°F80°F

Water Limits

Min. Entering Water 55°F55°F40°F40°F

Normal Entering Water 85°F70°F85°F70°F

Max. Entering Water 110°F90°F 110°F90°F

NOTE: This equipment is designed for indoor

installation ONLY.

When the disconnect switch is closed, high voltage is

present in some areas of the electrical panel. Exercise

caution when working with the energized equipment.

1. Adjust all valves to the full open position and turn

on the line power to all heat pump units.

2. Operate each unit first in the cooling mode. Room

termperature should be in the normal range (i.e.,

approximately 70°to 75°F DB and 61°to 65°F

WB). Loop water temperature entering the heat

pumps should be at least 70°F but not in excess of

110°F. Refer to Table 3 for more specific informa-

tion on the operating parameters of CS/CL units.

NOTE: Three factors determine the operating limits

of a CS/CL unit: (1) returen air temperature, (2)

water temperature and (3) ambient temperature.

Whenever any one of these factors is at a minimum or

maximum level, the other two factors must be at

normal levels to ensure proper unit operation. Flow

rates must be at ARI rated standards.

Unit Start-up / Cooling

a. Turn the unit thermostat to the cooling position

and turn the fan speed switch to "HI". If the unit has

an optional MCO thermostat, set the selector switch

to cool. Both the fan and compressor should run.

b. Check for cool air delivery at system grille a few

minutes after the units have begun to operate. List

the identification number of any machines that do

not function at this time.

c. Check the elevation and cleanliness of the

condensate lines; any dripping could be a sign of a

blocked line.

3. Operate each heat pump in the heating cycle immedi-

ately after checking cooling cycle operation. A time

delay will prevent the compressor from

re-starting for approximately three minutes.

Operating Limits

Environment: This equipment is designed for indoor

installation ONLY.

Power Supply: A voltage variation of +/- 10% of

nameplate utilization voltage is acceptable. Three phase

system imbalance must not exceed 2%.

CS Unit Starting Conditions: CS Units start and

operate in an ambient of 50°F with entering air at 50°F,

entering water at 60°F and with both air and water at the

flow rates used in the ARI Standard 320-86 rating test for

initial start-up in winter.

CL Unit Starting Conditions: CL Units will start and

operate in an ambient of 40°F with entering air at 40°F,

with both air and water at the flow rates used in the ARI

Standard 320-86 rating test, for initial start-up in winter.

Operating Limits

Note: Minimum air and water conditions can only be used

at ARI flow rates. Only one maximum or minimum value

may be used with CS Units. All other parameters must be

at normal conditions. CL Units may have up to two values

at maximum or minimum with all other parameters at

normal conditions.

NOTE: These operating limits are not normal or

continuous operating conditions. It is assumed that

such a start-up is for the purpose of binging the

building space up to occupancy temperature.

Use the procedure outlined below to initiate proper unit start-up:

CS Units CL Units

Page 10

Unit Start-Up / Heating

a. Adjust the unit thermostat to the warmest setting

and turn the fan speed switch to "HI". If the unit has

an optional MCO thermostat, set the selector switch

to heat. The blower should start immediately and

after the time delay is complete the compressor will

start.

b. Once the unit has begun to run, check for warm

air delivery at the unit grille. Again the installing

contractor must list the serial number of any

machine that does not function.

4. Log the unit operating conditions at initial start-up

for each unit to establish a permanent operating

record.

5. If the unit fails to operate, conduct the following

checks:

a. Check the voltage and current. They should

comply with the electrical specifications described

on the unit nameplate.

b. Look for wiring errors. Check for loose terminal

screws where wire connections have been made on

both the line and low-voltage terminal boards.

c. Check for dirty filters. A clogged filter will cause

safety cutouts to stop unit operation.

d. Check the supply and return piping. They must be

properly connected to the inlet and outlet connec-

tions on the unit.

e. If the fan fails to operate, check to see that the fan

wheel turns freely and that it is secured to the shaft.

Also, determine whether the fan operates during

both the heating and cooling modes.

f. If the checks described above fail to reveal the

problem and the unit still will not operate, contact a

trained service technician to ensure proper diagno-

sis and repair of the equipment.

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